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Old 08-08-2018, 10:54 AM   #1
seventune
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Default The '99 STI that wasn't supposed to be a project!

Hey everyone, I've always been on and off NASIOC checking out builds and looking at info so decided it was time to contribute with a build of my own. I'm a fabricator by trade and have been building all sorts of bits for cars for nearly 10 years now. Hopefully this goes some way to explaining why I've done some of the things I've done in this build. There are really two parts to this build and there was a large changing in direction after a 2nd engine build which i will explain along the way.... there is a fair bit to cover so bare with me as I mill through the build so far!!!

So where better to start than with the way i purchased the car? Its a '99 STI with 2.1 stroker motor. I wasn't really sure what was in the motor other that the EJ257 crank, after market pistons and Rods, generic intercooler kit, MD321T turbo, unequal length tube headers and 3" exhaust leading into a Blitz NUR spec, aftermarket in tank pump and larger injectors. Had an Exedy organic clutch, 6 speed gear box and R180 diff, Brembo 4 pot conversion, Alcatek ECU. It was a good quick road car that was good fun to drive....

This car was bought to be a decent daily with what i had hoped was going to be little hassle.... oh how i was wrong!!!

some pics:













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Old 08-08-2018, 10:59 AM   #2
seventune
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Now as it turned out the NUR spec had lost all its packing in the exhaust and as such was acting like a huge megaphone that even by my standards was way too loud. So I took the end off and made a more subtle rear box with a 3.5" exit to tone down the noise...







I also took this oppertunity to change the intake pipe and swap the filter to a larger B&M item and add a Tial BOV to the system....





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Old 08-08-2018, 11:13 AM   #3
seventune
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The next part of the plan was to move the turbo, add an external wastegate (my actuator had broken) and rotate the inlet. This ment a few extra mods to the alternator, a small section of the wiring and the intercooler pipes.



Here with the Alternator moved or flipped:



With the new intercooler pipes,



So this was fine for months, had a few ECU tweaks to match the new arrangement in the engine bay and all was well.... Until I came off throttle on the way home from work one night and the motor let go in spectacular fashion.... The following weekend i had the motor out and started to investigate the issue....
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Old 08-08-2018, 11:20 AM   #4
seventune
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Just taking the inlet manifold off i could see loads of water which had led me to believe that the liners had split. So with the motor out I put in in the back of the workhorse and took it up to the shop for stripping....







You can see here in the first place its an open block which i didn't know, you can also see a lot more water!!!



A very eaten alive piston!!!





A nice big crack!!!



What was a piston!!!



So with this amount of damage a new plan was needed along with a block....
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Old 08-08-2018, 11:27 AM   #5
seventune
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It just so happened that I stumbled across this on my search for a new set of crank cases.... This had also been machined for 14mm head studs and rear thrust bearing to take the EJ257 crank. It felt like a pretty big win....



With some aid in the way of parts from Rodger Clark Motorsport i got new head gaskets, 14mm studs, 13mm oil pump, ACL bearings along with a hole host of other new seals an bearings to make the EJ22 sing









Now the EJ22 as it turned out was a closed deck block either so in aid of trying to make this build more reliable I decided to pin the engine with series of dowels to reinforce the liners so that hopefully they wouldn't split again like last time.... Here is a pic after they were put in and the surface machined flat...

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Old 08-08-2018, 12:19 PM   #6
seventune
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So as the old pistons were shot I decided a nice new set of Wiseco pistons were in order. We use them a lot at the shop along with Woosner. Wiseco don't make EJ22 pistons so a set of custom ones were ordered to suite an oversized block and EJ257 crank. Also at the time a set of new rods were ordered from Arrow Precision.



With pistons in hand they, the block and the 'new' second hand STI 5 heads went off to James at Grace Engineering for machining, boring and just a general good old fashion clean up The cylinders were bored to suite the new pistons and heads rebuilt with new stem seals, crower valves, valve seats and retainers before being shipped back to me.

In the mean time Turned my focus to other parts of the build. The MD321 Turbo took a beating when the engine went pop so that needed replacing. I didn't have the cash to go out and buy a 1700+ unit so i opted to use a turbo i already had from an RX7 project that never got finished and eventually sold.... That turbo was a GT4094.... a bit of a lump! So a new set of headers was in order so I got some 321 stainless pipe in a set about the header...



This i decided to build at home on the block that ate itself before....





And here with the down pipe and MV-R wastegate



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Old 08-08-2018, 12:26 PM   #7
seventune
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following this there began to be a few other things to consider, Fueling for example.... I got another inlet manifold that i could mod and change the angle of the throttle body so the I/C pipes didn't hit the bonnet quite so badly.... I also use some areomotive billet fuel rail to make some new top mount rails for the bigger injectors and cleaned up the inlet which kind of went like this....







Then on the dumby motor with the turbo and manifold in place....

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Old 08-08-2018, 12:37 PM   #8
seventune
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The idea with the turbo there is I cold use the bonnet scoop to feed an air box straight to the turbo so i made up an ally one and used an ITG Honda filter to drop in the top....





I built a swirl pot for the boot and decided to use Earl's -8 hard line for the fuel pump, filter, feed and return lines. Mainly because it looked pretty cool



There were also a few more ally bits made such as breather tanks, header tank power steering fluid tank and last but not least the new I/C pipes which all went together like so....

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Old 08-08-2018, 12:45 PM   #9
seventune
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Right some oily bits!!!

The heads a block returned so i could set about the build....



Crank and Rods. Now the crank was the unit that came out of the blown engine. This got sent off to a crank shaft specialist to be checked, measured and cleaned to make sure it wasn't damaged in any way....











Cosworth belt kit :



And look it almost looks like an engine again!!!

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Old 08-08-2018, 01:04 PM   #10
seventune
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With the new power had to come a new clutch. I decided to use a 7.5" twin plate QuarterMaster unit. I much higher torque rating than i would need and super small and lightweight. This in turn led to a new flywheel to suite and hydraulic push type release bearing. So parts were sourced and a few bits machined so it all fitted together....







You can see the chromemoly unit from TTV Racing is far lighter at just 3kg



time to make a spacer plate







here with the AP push bearing in place:



on the box with the lines made up to just for good measure... and because it needs those to work!
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Old 08-08-2018, 01:27 PM   #11
seventune
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So with the motor done, the car back at the an all together i could finally turn the key and get this wee old girl back on the road....

This is a pic of the loom going back in the day before it was fired up...



So yes turn the key fires up and it sounds like a bag of nails.... to say i was a very unhappy chappy was a huge under statement....

backout comes the motor again....

Upon inspection and I've tried to see if i have any pics but i can't seem to see any it turns out that the crank and wrecked the ACL bearings.... so not only did they need replacing again i also needed a new crank.... this time no chances and i did what i should have done in the first place:





nice new Nitrated crank straight from Subaru courtesy of Rodger Clark Motorsport again

So this took a few days to come and again with time to think about things i decided to take about 50 steps back and do loads more! this will give you an idea of what i did....





That's right i decided to go V-mount.... why you ask? I still have no idea to be fair.... I like the set up, its a bit WRC and people seem to have pretty good results with them.... Of course not just a new intercooler core but a new radiator core too. These both came from Pace Products and i had to set about make the end tanks so it would all fit in nice and snug... You can see in these pics I had already got started with the rad end tanks as they were nice and easy. These were done using some 2mm ally tube that was cut into halves and welded on to keep them nice and slim.... The Intercooler tanks were a little more complicated but came out really nicely..... So here is how they were made:

Started off with some sheet metal and essentially beat them into two halves so as to form a slight curve to encourage air flow:



The ends and side where simply some shaped section welded both inside and out... the whole piece is made from 3.2mm ally. Then you can see the inlet and out lets are welded on for the pipes to join with... These are 2.5" in diameter....







one the core and then the last two are with it painted... and i have to say i was really happy with how it turned out...
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Old 08-08-2018, 01:28 PM   #12
seventune
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Old 08-08-2018, 01:37 PM   #13
seventune
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And the rad:



These needed a fair bit of modding to get in the car in terms of the cross members behind the bumper. So the top slam panel came out as did the bottom support which was replaced with a section of T45 tube....





This allowed me to get the cooler and rad in, you can also see the oil cooler in this one. I made up some small "A" brackets for the bottom of the cooler and top of the rad but i wasn't happy with the rad position when the fans were put on which led to the bottom bar being removed and an extra support for the rad.....



With the new pipes





with the bumper back on, you'd never even know



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Old 08-08-2018, 01:46 PM   #14
seventune
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A few extra additions came while i was doing all that:

pedal box: The cylinders have a kick plate that goes over them...



Jazzy deep OMP wheel and quick release.... I ended up making an adapter for this as getting a boss for the Impreza steering column was a nightmare!!!! Also a sandwich plate was made up because the OMP had no place for a horn to sit on the quick release's flush mounting face!





chopped and turned from the stock Impreza unit



machined form a lump of ally so it would be an interference fit with the 1st piece and then welded:











You can also see some toggle switches in those pics. These are for the fuel pumps, fans, ignition and engine start....
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Old 08-08-2018, 01:51 PM   #15
seventune
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Some new shoes were also ordered.... now i was in a state of pure overwhelming "what tire" syndrome.... A friend of mine said they had just put some Nangkang (I shuddered at that point too) NS2-R tires on his lotus and said they were amazing in the dry and even pretty good in the wet so I took the plunge....







They looked the part at least!!!
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Old 08-08-2018, 01:54 PM   #16
seventune
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Time for another addition to the bonnet and also an STI 6 rear wing that I had to paint white...







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Old 08-08-2018, 02:47 PM   #17
seventune
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Anyway so I guess I've gone a little off the boil on the motor front! So the new crank came, the engine cases went off to be checked out and when i got the green light it all when back together for a second time. Lovely Job....



After a day or so of putting the motor in, doing all the ancillaries etc she was again ready to oil up and get fired.... Oh how i had missed that flat four sound....

Cranked over brilliantly and very strong but would the thing fire? Of course not. SO down to the Jawa Juice shop (petrol station) for some new juice in a jerry can, filled the car and still nothing. In to double and triple check mode we go!!! Nothing, literally couldn't find a single thing. Fuel was getting through, injectors are firing, have a spark.... so why won't this dam thing fire up.... By that stage it was time go home before the kerosene and a lighter came out!!!!

The following morning i had decided to check all the sensors and this is where I found the issue but not with the sensors with the Alcatek ECU.... this led to a few phones, emails, voice mails, more phone calls and emails and i got no response from them at all.... So in the bin did the Alcatek go and a new ECU employed for the task....



Syvecs S6 GP.... why not the plug and play? Because by this point I didn't trust my engine harness/loom so i wanted to make a new one.... Along with this like the Alcatek the Injectors I'm using are low impedance so the AEM injector driver was required again



With the new setup growing the RC injectors were ditched in favor of some bigger Bosch units, again top feed. I was also growing unhappy with the way the fuel rails looked with the welded -6 feeds some some additional Aeromotive billet rail was ordered and this time threaded for ally AN fittings.



had to machine a little of the ribbing off to create space for the brackets to be welded on....





Late spec coil packs were also bought in favor of the single coil set up....

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Old 08-08-2018, 02:47 PM   #18
seventune
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Another little mod I wanted to do was to move the indicators from the front bumper as i intended to use those gaps to help feed air to the oil cooler and power steering cooler so I dismantled a pair of bike indicator and jimmy'd them into the side lights... While i was on the lights it was time to ditch the chrome look too and make them black...









And the head lights....





much better....
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Old 08-08-2018, 02:54 PM   #19
seventune
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It was around this time that work, life and health got in the way of the build so I started doing little bits here and there that were not entirely necessary but was a way to keep my mind on the build.... this started with the Intercooler pipes.... I had ordered some 2.5" grade 2 titanium and this got chopped, tacked, heated and welded and for what took many hours of work for a purely aesthetic mod!!!! but I looks cool so I'm happy









and the other side done in the same way:



AANNNNND then this kind of happened!!!





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Old 08-08-2018, 03:01 PM   #20
seventune
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Rota Grid drifts in an 18x10 ET15.... and yes i also used a 20mm PCD adapter as these rims are 5x114.3. They are wrapped in 265/35/18 RS-595 rubber.... lovely in the dry and deadly in the wet!!!







Then came the arch modding







A very budget way to get an idea of how you would like a side skirt to look



With this i decided to get the car back home where i could spend some weekends and evening doing the body work at my leisure... so off she went....



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Old 08-08-2018, 03:08 PM   #21
seventune
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Right so on go the 18x10j all round so we can get on with the arches....



There isn't a whole load to say here other than I wanted a fat, wide angry Impreza so here are some pics as I went along fitting a tweaking each piece....









A TA front spoiler was bought from ABW along wid some wide skirts, but they were not wide enough so I had to add quite a bit in!



after many hours of messing around!!

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Old 08-08-2018, 03:12 PM   #22
seventune
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The car BC racing coilovers on which were shocking, knocking, rattling bits of awful metal so they came off in favor of some XYZ Racing units. They have great adjustment and are a great fast road damper. White roll bars, anti lift and drop links were also bought along with a few gauges.....











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Old 08-08-2018, 03:13 PM   #23
seventune
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Bit more on the body and an STI 8 style scoop added:



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Old 08-08-2018, 03:36 PM   #24
seventune
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Next trick was priming the front end ready for paint:





With the white and black on there properly it was starting to look how i wanted it too....



Now don't worry in the next pic!!! the reason for the wheel swap was that the GTR needed new tyres and the rota wheels had new tyres on so they went straight on the GTR and the GTR wheels on the scoob. Now after much deliberation these wheels will be staying on the scoob as they are considerably lighter than the Rota Grids but will require some painting to get rid of the chrome!

You'll notice the appearance of the GT wing and front splitter too



Another addition came by way of chance through a friend who had to replace his seats for newer version due to homologation rules.... so i ended up with these:



in with the new rails.....





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Old 08-08-2018, 03:42 PM   #25
seventune
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Now I don't have 1,000s of spare cash so i have to do the splitter/under tray the cheap way. A big sheet of marine ply! I made up a frame and made some mounting point on the car and it was just about there.... Now the other ting is that still currently I havent made the supports adjustable yet but they will get rose jointed at some stage and the metal frame might get redone in ally too but for now its just fine....





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